Guardrail support, attachment, and positioning block

ABSTRACT

A guardrail support, attachment and positioning block used to space guardrails from support posts is disclosed. The positioning or spacer block is a generally rectangular block having corded-out cavities to reduce weight and tabs or projections for cooperatively engaging the sides and top of a support post as well as the edges of the guardrail during roadway safety barrier system installation. Webbing within one or more of the cavities may be used for additional structural support. To optimize the strength to weight characteristics of the spacer block, the spacer block may be formed by low-pressure injection molding. The spacer block may also be formed from virgin and/or recycled plastic material and/or include virgin or recycled rubber material, such as that obtained from the regrind of used tires, and/or another elastomeric materials from other sources.

RELATED APPLICATIONS

[0001] This application is a continuation-in-part of U.S. patentapplication Ser. No. 10,001,903, filed Nov. 15, 2001 and entitled“Guardrail Support, Attachment, and Positioning Block” which claimedpriority from United States provisional application Serial No.60/249,037, filed on Nov. 15, 2000.

TECHNICAL FIELD OF THE INVENTION

[0002] The present invention relates generally to highway safety systemsand, more particularly, to spacer blocks for attachment of guardrails tosupport posts.

BACKGROUND OF THE INVENTION

[0003] Guardrails are typically installed along highways as componentsin roadway safety barrier systems. The guardrails commonly used areusually formed as strips of material, typically twelve (12) gaugegalvanized steel Other materials commonly used in guardrail fabricationinclude aluminum, steel, fiberglass, or even synthetic materials. Mostsegments of guardrail are approximately twelve (12) feet in length andabout ninety (90) pounds in weight.

[0004] At least one configuration of a guardrail used includes acorrugation forming an undulating cross section. The undulating crosssection is employed in its capacity to absorb energy from the impact ofan out of control vehicle. Such energy absorption is desired in aneffort to prevent the vehicle from leaving the roadway or at least toinfluence the direction of the vehicle prior to it leaving the roadway.Typically, corrugated beams are about nine (9) inches wide, have twocrowns and are shaped substantially like the letter “W”. An alternatecorrugated guardrail embodiment is known in the industry as a thrie-beamguardrail. Thrie-beam guardrails typically have three crowns and aregenerally about one-third (⅓) wider than a conventional, two-crown, or“W”, guardrail.

[0005] In most roadway safety barrier systems, a plurality of guardrailsare typically linked together at their distal ends, either end to end,or overlapping, and are supported by a plurality of vertically orientedsupport posts. Among the support post configurations typically used are“I-beam,” round or square posts. The support posts used may befabricated from a variety of materials including wood, metals such asaluminum, steel, etc. Some support posts may also be formed from polymeror fiberglass materials. In place, driven into the ground a distancefrom the edge of the roadway and from one another, the support postswill typically yield under a certain amount of pressure either by movingwithin the ground or by bending in accordance with the deformation ofthe guardrail. Preferably, the support posts do not break off at groundlevel. Yielding or bending is preferred in an effort to assist theguardrail in dissipating the impact force received from an out ofcontrol vehicle.

[0006] In a typical roadway safety barrier system, a spacer block isdisposed between the guardrail and the support post such that theguardrail may be maintained a distance from the support post. Thespacing provided by the spacer block preferably helps keep anautomobile's wheels from coming into contact with the support posts andinitiating a roll of the vehicle. In addition, the guardrail provides arail or track for guiding the vehicle and providing at least someresponse time for the driver to regain control of the vehicle.

[0007] Conventional spacer blocks are typically made of wood. However,wood as a material for spacer blocks has many shortcomings. Among wood'sshortcomings as a spacer block material are that it deteriorates overtime, it is excessively heavy, it can give installers splinters and ittypically contracts and expands with seasonal changes. In addition, woodtends to leach out the chemicals typically used for pressure treatment,which chemicals may be toxic to the environment. While there are someplastic spacer block substitutes on the market, they are generallydeficient in that they are typically wood block designs formed fromplastic.

[0008] In most installation instances, it requires two to three peopleto attach a twelve (12) foot section of guardrailing to support postswhen using conventional spacer blocks. In the effort, installationtypically requires one person to hold the guardrail while another personaligns and holds the spacer block in position. A third person is oftenrequired to insert bolts or other attachment means through each systempiece for securitization thereof

SUMMARY OF THE INVENTION

[0009] In accordance with teachings of the present disclosure, aguardrail support, attachment and positioning block is provided. In oneembodiment, the block preferably includes a pair of side-walls coupledto a top and a bottom panel, thereby forming a generally rectangularblock having first and second faces. The block preferably furtherincludes, among other components, at least one mounting bore forcoupling a guardrail to a support post. The block preferably alsoincludes an engagement mechanism operable to engage the block with thesupport post and a resting mechanism operable to support the guardrailduring assembly.

[0010] In another aspect of the present invention, a method ofmanufacturing a spacer block for attaching a guardrail to a support postis provided. The method preferably includes forming a block, forming afirst aperture through the block and positioning an engagement mechanismon the block, the engagement mechanism preferably being operable toretain the block proximate a mounting position during assembly of aroadway safety barrier system.

[0011] In yet another aspect, the present invention provides a guardrailsupport assembly. The guardrail support assembly preferably includes asupport post and a spacer block. The spacer block preferably includes,among other characteristics, a top tab operable to engage the supportpost and maintain the spacer block in position.

[0012] In a further aspect, the present invention provides a method forassembling a roadway safety barrier system. The method preferablyincludes, among other steps, engaging a tab on a spacer block with asupport post such that the spacer block is retained proximate a mountingposition. The method preferably also includes engaging at least aportion of a guardrail with a support mechanism on the spacer block suchthat the guardrail segment may be retained in position proximate themounting position.

[0013] In another aspect, the present invention provides a roadwaysafety barrier system. The roadway safety barrier system preferablyincludes a guardrail, a support post and a spacer block coupled togetherby one or more attachment mechanisms. The spacer block preferablyincludes, among other elements, a positioning mechanism operable todepend the spacer block from the support during assembly of the roadwaysafety barrier system.

[0014] Further, the present invention provides a spacer block havingimproved strength, reduced weight, and competitive cost. In addition,the spacer block of the present invention, designed with the assemblyprocess in mind, enables an individual installer to erect and install aguardrail safety barrier system using spacer blocks supported by posts.

[0015] Plastic properties are different from those of wood. The presentinvention takes advantage of these different properties through the useof a new spacer block design. The spacer block of the present inventionmay employ plastic (polyethylene, PVC, polypropylene polyethyleneterephthalate, nylon), plastic/rubber, as well as other materials in itsconstruction. Through the use of such materials, the present inventionprovides a more resilient, elastic and flexible spacer block that isgenerally impervious to weathering, has increased longevity, andrequires little or no maintenance once installed.

[0016] It is an object of the present invention to provide a spacerblock enabling one person to install a roadway safety barrier system.

[0017] It is another object of the present invention to provide a spacerblock which is splinter-less, has a longer life span and is lighter thanwood.

[0018] It is yet another object of the present invention to provide aplastic/rubber composite spacer block that meets all requiredspecifications set forth by the Federal Highway Administration.

[0019] It is still another object of the present invention to provide aspacer block that is environmentally friendly and capable of beingmanufactured using recycled plastic, tires, and/or combinations thereof.

[0020] It is still another object of the present invention to provide aplastic-rubber composite spacer block that will meet or exceed thecapabilities of today's wooden block.

[0021] Yet another object of the present invention is to provide aspacer block embodiment that may be formed from structural foam in orderto optimize the weight to strength characteristics of the spacer block.

[0022] Other objects, features, and advantages of the invention will beapparent from the following detailed description taken in conjunctionwith the accompanying drawings showing a preferred embodiment of theinvention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0023] A more complete understanding of the present embodiments andadvantages thereof may be acquired by referring to the followingdescription taken in conjunction with the accompanying drawings, inwhich like reference numbers indicate like features, and wherein:

[0024]FIG. 1 is a perspective view showing a two crown guardrail roadwaysafety barrier system according to teachings of the present invention;

[0025]FIG. 2a is a perspective view showing a guardrail support assemblyaccording to teachings of the present invention;

[0026]FIG. 2b is an expanded view showing the engagement or positioningmechanism of the spacer block illustrated in FIG. 2a according toteachings of the present invention;

[0027]FIG. 3 is a perspective view showing a rear and side of oneembodiment of a spacer block according to teachings of the presentinvention;

[0028]FIG. 4 is a perspective view of the spacer block depicted in FIG.3 showing a front and side of the spacer block according to teachings ofthe present invention;

[0029]FIG. 5 is a perspective view showing an alternate embodiment of aspacer block according to teachings of the present invention;

[0030]FIG. 6 is a plan view showing the front of one embodiment of aspacer block according to teachings of the present invention;

[0031]FIG. 7 is a plan view showing an alternate webbing arrangement fora spacer block according to teachings of the present invention;

[0032]FIG. 8 is a plan view showing a spacer block for use with athrie-beam guardrail and utilizing a webbed reinforcement arrangementsimilar to that used in the spacer block shown in FIG. 6 according toteachings of the present invention;

[0033]FIG. 9 is a plan view showing a spacer block for use with athrie-beam guardrail and utilizing a webbed reinforcement arrangementsimilar to that used in the spacer block shown in FIG. 7 according toteachings of the present invention;

[0034]FIG. 10 is a side view of a spacer block formed from structuralfoam according to teachings of the present invention;

[0035]FIG. 11 is a top view, in section, showing a spacer block having acellular core and an integrated solid skin on each side thereofaccording to teachings of the present invention;

[0036]FIG. 12 is a plan view, in section, of the structural foam spacerblock illustrated in FIG. 10 showing a cellular core and an integralsolid skin, wherein the transition from skin to cellular core isgradual, according to the teachings of the present invention;

[0037]FIG. 13 is a perspective view showing a portion of a two-crownguardrail roadway safety barrier system incorporating a structural foamspacer block according to the teachings of the present invention;

[0038]FIG. 14 is a perspective view of a guardrail support assemblyincorporating a structural foam spacer block according to the teachingsof the present invention; and

[0039]FIG. 15 is a perspective view showing a roadway safety barriersystem incorporating thrie-beam guardrails according to teachings of thepresent invention.

DETAILED DESCRIPTION OF THE INVENTION

[0040] Preferred embodiments of the invention and its advantages arebest understood by referring to FIGS. 1 through 15 of the drawings, likenumerals being used for like and corresponding parts of the variousdrawings.

[0041] As illustrated in FIGS. 1 through 2b, spacer block 11 of thepresent invention may be mounted to a support post 30, such as an I-beamsupport post, such that spacer block 11 may cooperatively engage andsupport a guardrail segment 14 thereon. The roadway safety barriersystem 10 of FIG. 1 preferably includes a plurality of spacer blocks 11,support posts 30 and guardrail segments 14. An alternate embodiment ofroadway safety barrier system 10 and spacer block 11 for use withthrie-beam guardrail segments 15 is illustrated in FIG. 15 and describedin further detail below.

[0042] In FIGS. 1 through 4, spacer block 11 is shown with a removableand slidable top tab 40 for engaging a top edge of support post 30. Sidetabs 42, illustrated in FIGS. 2a, 3 and 4, for preventing lateralmovement of spacer block 11 may also be included. In one embodiment,guardrail 14 preferably rests on a bottom or support tab 64, illustratedin FIG. 4, extending from front face 12 of spacer block 11. Duringinstallation, bottom tab 64 preferably aids in the support and alignmentof guardrail 14 for attachment to support post 30 with one or moreattachment mechanisms 13 (e.g., bolts) extending through holes ormounting bores 28 of spacer block 11 and support post 30. ConventionalI-beam support posts 30 generally have at least one hole punched into aflange 54 on one side of the support post 30 as illustrated in FIG. 2a.

[0043] A spacer block 11 for use with conventional two crown (“W”)guardrails or other conventional longitudinal rail members is generallyshown in FIGS. 1 through 6, 7, 10 and 12 through 14. Such a spacer block11 is preferably about four (4) inches wide, about seven and one-half(7½) inches deep, and about fourteen (14) inches long.

[0044] a spacer block 11 formed in accordance with teachings of thepresent invention preferably includes front face 12. Front face 12 maybe a generally flat solid surface. Alternatively, front face 12 may bewebbed, curved, corrugated or formed to correspond to the shape of aguardrail 14. Similarly, rear face 16 may be concave or include alongitudinal depression operable to fit around support posts 30.

[0045] Front face 12 is preferably connected to rear face 16 by a pairof spaced apart, opposing side-walls 18 as well as a top panel 20 and abottom panel 22. The interconnections between side-walls 18, top panel20, and bottom panel 22 may have rounded shoulders 24, see FIGS. 1through 4, or squared shoulders 26, see FIG. 5.

[0046] As illustrated in FIGS. 3 and 5, spacer block 11 may include atop cavity 34 and a bottom cavity 36 separated by a medial wall 38horizontally disposed between front face 12 and rear face 16. A pair ofmounting bores 28 are preferably disposed proximate to or through medialwall 38. Corded-out cavities 34 and 36 may be reinforced with webbing,solid block materials, gel material, foam, or liquids such as water orglycol, as well as mixtures thereof to aid in the dissipation of stressor impact force.

[0047] As mentioned above, one embodiment of spacer block 11 preferablyincludes a pair of mounting bores 28 formed through medial wall 38.Mounting bores 28 are preferably oriented horizontally, travellingbetween front face 12 and rear face 16, side by side, to facilitatealignment of the one or more mounting bores 28 with the one or moreoffset holes 55 preformed in a typical support post 30. Orientingmounting bores 28 as described preferably enables a single installer toposition the mounting bores 28 for quick alignment and attachment of aspacer block 11 and guardrail 14 to support post 30.

[0048] As illustrated, spacer blocks 11 may include at least one andpreferably a plurality of mounting bores 28 extending through front face12 for cooperative engagement of an attachment mechanism 13 extendingthrough guardrail 14 and spacer block 11, securing their attachment tosupport post 30. In a preferred embodiment, mounting bores 28 extendthrough both front face 12 and rear face 16. In addition, mounting bores28 may extend through medial wall 38 connecting front face 12 and rearface 16. According to teachings of the present invention, a sleeve 32formed from a cylinder having a bore therethrough may be used as aremovable spacer means for insertion between a hole formed in front face12 and rear face 16. Sleeve 32 preferably abuts an interior surface offront face 12, extends through a cavity formed in the interior of spacerblock 11, interconnects with an interior surface of rear face 16 andprovides additional structural support.

[0049] Spacer block 11, as mentioned above with reference to FIGS. 1through 4, preferably also includes a top tab 40 fixedly attached to toppanel 20. Tab 40 may also be provided as a removable or slidable tabhaving projections for cooperatively engaging grooves formed in channel43, such as in a tongue and groove arrangement. Tab 40 preferablyextends beyond rear face 16 of spacer block 11 such that spacer block 11may be engaged with the top of a support post 30 and depend therefrom,see FIGS. 1 through 2b and 13 through 15. In alternate embodiments,positioning or engagement tab 40 may comprise a flat plate, a ring toengage a cylindrical post or any other form useful for engaging supportpost 30 of different configurations according to teachings of thepresent invention.

[0050] The embodiment of engagement tab 40 shown in FIGS. 1 through 5includes projecting members or fingers 50 extending downward from tab40, enabling tab 40 to rest on, be positioned on, or otherwise engagethe top of an I-beam shaped support post 30. In such engagement, fingers50 preferably extend behind flange 54 of support post 30 to thereby holdspacer block 11 proximate a mounting position on support post 30.

[0051] To facilitate a movable positioning tab 40, a groove or channel43 may be formed or cut in top panel 20 on spacer block 11. As shown inFIG. 4, a leg 48 that extends from a bottom surface of tab 40 andmovably engages the top of the channel 43 to provide additionalstructural support to tab 40 may also be included.

[0052] As shown in FIG. 5, first and second channels, 56 and 58respectively, may be formed in top panel 20 of spacer block 11. Tabs 41and 46 may be provided, attached to the top surface of top panel 20, andpreferably extend beyond rear face 16 of spacer block 11. Similar to toptab 40, tabs 41 and 46 are preferably flanges 45 align with one anotheror that there be a corresponding number of each on the respective sidesof spacer block 11. The inclusion of at least one side tab 42 or sideflange 45 aids in positioning spacer blocks 11 with respect to thevertical sides or flanges 54 of support post 30. Side tabs 42 or sideflanges 45 may be integrally formed on spacer block 11 or attached by aholding means such as a screw or projection for engaging a hole (notexpressly shown) formed in spacer block 11. Spacer block 11 may bereadily aligned to its proper orientation or in a mounting positionthrough the aid of side tabs 42 or side flanges 45 and tab 40.

[0053] Spacer block 11 preferably also includes a support tab 64operable to support or rest at least a portion of a guardrail 14thereon. As shown in FIGS. 4, 6, 7 and 10, tab 64 may be provided as anextension from bottom panel 22 or front face 12. Alternate positions ofsupport tab 64 are considered within the scope of the present invention.By allowing guardrail 14 to rest on support tab 64, the alignment ofmounting bores 28 with one or more holes in guardrail 14 and supportpost 30, and the installation of the same, may be simplified.

[0054] To permit stacking or nesting of stored spacer blocks 11, asillustrated in FIGS. 3, 7 and 9, a recess or notch 60 may be formed orcut into bottom panel 22, proximate rear face 16. Notch 60 preferablyallows for the cooperative engagement of support tab 64 therewith suchthat spacer blocks 11 may be positioned one upon the other for storage,transport or other purposes.

[0055] Spacer block 11 may be formed or molded such that front face 12is slightly shorter than rear face 16, resulting in top panel 12 andbottom panel 22 inclining toward one another slightly (not expresslyshown) at front face 12 to facilitate the removal of spacer block 11from the mold. Notch or recess 60 of spacer block 11 may also be formedon bottom panel 22 as a declining channel extending from rear face 16toward front face 12 and preferably does not extend through an interiorsurface of bottom panel 22.

[0056] Spacer blocks 11 built in accordance with teachings of thepresent invention may be molded into specific embodiments enabling themaximization of structural integrity while maintaining controlledflexibility. These traits may be leveraged by using, among otheroptions, reinforcing webbing, and various rubber and thermoplasticcompositions.

[0057]FIGS. 6 and 7 show alternate embodiments of spacer block 11 of thepresent invention using webbing within top cavity 34 and bottom cavity36. Two reinforcing webbing configurations are shown in FIGS. 6 and 7.As illustrated, rear face 16 of spacer block 11 shows webbing formed bycombining various lengths of lateral, longitudinal, and transversemembers having cavities thereinbetween. The members are preferablypositioned to increase structural strength while aiding spacer block 11in the control of compression and flexing forces. A webbed reinforcementstructure preferably also contributes to minimizing the weight of spacerblock.

[0058] As shown in FIG. 6, one embodiment of spacer block 11 preferablyincludes webbing which extends from an interior surface of front face12, through cavity 34 and/or 36, and having a distal end equal in lengthto side-walls 18, terminating to form rear face 16. In such a webbingconfiguration, preferably extending from a center of first cavity 34from the interior surface of front face 12 is first cylindricalreinforcement member 72. A corresponding second cylindricalreinforcement member 74 is preferably included extending from theinterior surface of front face 12 through second cavity 36. In each ofcavities 34 and 36, the webbing preferably comprises runners extendingfrom first and second cylindrical reinforcing members, 72 and 74respectively, to the interior surfaces of side-walls 18, top panel 20,bottom panel 22 and medial wall 38.

[0059] Specifically as shown in FIG. 6, within first cavity 34, firstrunner 76 preferably extends between top panel 20 and cylindricalreinforcing member 72. A pair of second runners 78 preferably extendbetween cylindrical reinforcing member 72 and the corners connecting toppanel 20 with side-walls 18. A pair of third runners 80 preferablyextend between cylindrical reinforcing member 72 and side-walls 18. Afourth pair of runners 82 preferably extend between cylindricalreinforcing member 72 and medial wall 38, forming a teardrop shapedcavity thereinbetween.

[0060] Within second cavity 36 of spacer block 11, illustrated in FIG.6, is a first runner 176 preferably extending between bottom panel 22and cylindrical reinforcing member 74. A pair of second runners 178preferably extend between cylindrical reinforcing member 74 and thecorners connecting bottom panel 22 with sidewalls 18. A pair of thirdrunners 180 preferably extend between cylindrical reinforcing member 74and side-walls 18. A fourth pair of runners 182 preferably extendbetween cylindrical reinforcing member 172 and medial wall 38, forming ateardrop shaped cavity thereinbetween.

[0061] The spacer block 11 embodiment illustrated in FIG. 7 hasdimensions, features, and webbing similar to the embodiment of spacerblock 11 illustrated in FIG. 6. However, the embodiment of spacer block11 illustrated in FIG. 7 differs from that illustrated in FIG. 6 in thatthe reinforcement webbing illustrated in FIG. 7 does not utilize runner76 extending between top panel 20 and cylindrical reinforcing member 74or the vertical runner 176 extending between bottom panel 22 andcylindrical reinforcing member 74. In addition, the embodiment of spacerblock 11 depicted in FIG. 7 includes notch 60 formed in bottom panel 22,proximate rear face 16. As illustrated, notch 60 preferably forms apocket and does not cut through an exterior surface of bottom panel 22.

[0062] Illustrated in FIG. 8 is an elongated embodiment of a spacerblock 11 designed for use with thrie-beam guardrails. Illustration ofone embodiment of a roadway safety barrier system 10 using oneembodiment of a thrie-beam spacer block 11, as shown in FIG. 8, isdepicted in FIG. 15. Elongated spacer block 11 of FIG. 8 preferablyincludes additional third cavity 35, medial wall 138 and mounting bores128, disposed between first cavity 34 and second cavity 36. Thrie-beamspacer block 11 of FIG. 8 preferably utilizes substantially the samereinforcing webbing configuration illustrated in FIG. 6. A spacer block11 designed for use with a thrie-beam guardrail 15, illustrated in FIG.15, is preferably approximately four (4) inches wide, about twenty-one(21) inches long, and about seven and one-half (7½) to eight (8) inchesthick. The depth, length or other dimensions may vary to correspond withthe dimensions of a selected guardrail or support post. However, thefour (4) inch wide dimension, although not critical, is preferablymaintained at about four (4) inches or approximately equal to thethickness of support post 30, excluding side flanges 45 or side tabs 42.

[0063] Preferably included within third cavity 35 of elongated spacerblock 11 is a pair of runners 278 extending between cylindricalreinforcing member 272 and medial wall 38, forming a teardrop shapedcavity thereinbetween. A pair of runners 280 preferably extend betweencylindrical reinforcing member 272 and side-walls 18. A pair of runners282 preferably extend between cylindrical reinforcing member 272 andmedial wall 138, forming a teardrop shaped cavity thereinbetween.

[0064] The structural integrity of the various embodiments of the spacerblocks 11 of the present invention may be attributed to the lightweightcomposite materials and the reinforcing webbing which preferably providefor rigidity and controlled compression of spacer blocks 11 under load.

[0065]FIG. 9 shows a second elongated embodiment of spacer block 11 foruse with thrie-beam guardrails. See FIG. 15 for one embodiment of aroadway safety barrier system 10 capable of using a thrie-beam spacerblock 11 as shown in FIG. 9. As illustrated in FIG. 9, elongated spacerblock 11 may include third cavity 35, medial wall 138 and mounting bores128, disposed between first cavity 34 and second cavity 36. Theelongated spacer block 11 of FIG. 9 preferably utilizes substantiallythe same webbing configuration as the “W” guardrail spacer block 11embodiment illustrated in FIG. 7. Similar to the elongated spacer block11 embodiment of FIG. 8, the thrie-beam spacer block 11 illustrated inFIG. 9 is preferably approximately four (4) inches wide, abouttwenty-one (21) inches long, and about seven and one-half (7½) to eight(8) inches thick. As mentioned above, the depth, length or other spacerblock 11 dimensions may vary to correspond to the dimensions of aselected guardrail 15 and/or support post 30. However, the four inch (4)wide dimension, although not critical, is preferably maintained at aboutfour (4) inches or approximately equal to the thickness of a supportpost 30, excluding any side flanges 45 or side tabs 42.

[0066] In addition to or in place of the webbed reinforcement structuresdescribed above, it is contemplated that all or at least a portion of aspacer block may be filled with foam, gel, finely ground solid material,or a liquid such as water, alcohol or glycol. Alternatively, one or moreof cavities 34, 35 or 36 may contain a bag filled with one or morematerials to cushion and absorb impact with a roadway safety barriersystem. The materials that may be contained within spacer block 11 orincluded in a container inserted into the webbing or into one or more ofcavities 34, 35 or 36 formed within spacer block 11 may be removable,such as through the use of a water bag or a deformable plastic containersuch as a jug. In addition, a cellular core may be used for impactabsorption within cavities 34, 35 or 36, just as an impact absorbingblock filled with cellular material, gel, or a liquid may be disposedwithin one or more cavities 34, 35 or 36 of spacer block 11 according toteachings of the present invention.

[0067] As mentioned above, spacer blocks 11 made in accordance withteachings of the present invention may incorporate a variety ofmaterials into their construction. One embodiment of a spacer block 11incorporating teachings of the present invention incorporates structuralfoam into its composition. A structural foam spacer block 11incorporating teachings of the present invention, such as the structuralfoam spacer blocks 11 illustrated in FIGS. 10 through 14, is preferablymolded and preferably includes a cellular core and an integral solidskin, wherein the transition from skin to core is preferably gradual, asshown generally at 90 in FIGS. 11 and 12. The solid skin preferablygives a molded spacer block 11 its form and toughness, while thecellular core preferably contributes to the attainment of highstrength-to-weight characteristics. In one embodiment, the skin of astructural foam spacer block 11 may be up to one-half (½) inch thick.Preferred skin thicknesses range down from one-quarter (¼) inch thick toone-eighth (⅛) inch thick.

[0068] In general, there are two basic types of plastics available forcreating structural foam spacer blocks 11, thermoset materials andtermoplastic materials. Thermoset materials, such as polyurethane, maybe produced by polyaddition of reactive components such as polyol andisocyanate. Thermoplastic materials typically require the addition ofphysical or chemical blowing agents to produce foam and do not undergochemical change. Some blowing agents decompose when heated to processtemperature to evolve a gas such as carbon dioxide. (During processing,the exotherm generated by the reaction vaporizes a blowing agent thatcauses the mixture to expand.) Often, sodium bicarbonate or ammoniumcarbonate is used to form cellular or sponge rubber. Halocarbons andmethylene chloride may be used in urethane, pentane in expandedpolystyrene, and in some cases, hydrazine for foamed plastics.

[0069] Spacer blocks 11 using plastic and/or rubber components aregenerally limited to solid wall thicknesses of about four (4)millimeters. The wall thickness of a structural foam spacer block 11using plastic and/or rubber components, on the other hand, is preferablynot less than about four (4) millimeters in order to gain full advantageof a foam webbing structure between two layers of skin. Thus, greateroverall wall thickness may be obtained by using structural foam.Additionally, structural foam spacer blocks 11 have few, if any, sinkmarks due to residual gas pressure in the cells. This allows thematerial to expand internally during cooling of the part while holdingthe skin firmly against the mold walls.

[0070] Because of their cellular structure, spacer blocks formed fromstructural foam are virtually stress-free, resulting in bowing andwarping being greatly reduced. In addition, because of its cellularstructure, less resin is required during fabrication, which results in apart three (3) to four (4) times more rigid than a solid part of thesame weight. Consequently, spacer blocks 11 made in accordance withteachings of the present invention may be made from commodity plasticssuch as polystyrene and polyethylene with or without rubber in a loadbearing application.

[0071] Properties of a structural foam spacer block 11 depend on thebase polymer, overall part density, density distribution, skinthickness, cell shape and size, among other variables. Each of thesevariables may be affected by the processing method, process variables,wall thickness, and mold design.

[0072] The density of structural foam generally varies across its crosssection and is typically lowest in the core. As the distance from thecenter of a foam block increases, the cells generally get smaller untilthey “disappear” near the outer skin, see generally at 90 in FIGS. 11and 12. One objective of such a composition is to produce a part withhigh skin density, low core density and without the presence of voids.The range of available densities varies in the present invention fromabout thirty (30) percent in the center to one hundred (100) percent atthe outer skin. Also, the overall part density, density distribution,skin thickness, cell shape and size depend upon the mold cycle which mayvary between one-half (½) to ten (10) minutes.

[0073] A preferred embodiment of spacer block 11 may be formed with alow-pressure injection molding machine using thermoplastics and/orrubber. A screw may be used to plasticate a mixture of polymer and up toone (1) percent chemical blowing agent, preferably up to one-half (½)percent, wherein the screw barrels have zones maintained at differenttemperatures and are arranged so that the blowing agent is maintainednear the nozzle. A foamable mixture may thereby be produced, pumpedunder pressure to an accumulator and stored in a molten state at apressure higher than the foaming pressure. Upon opening a valve in thenozzle, a portion of the foamable mixture may be discharged from theaccumulator into the mold. The mold cavity is then filled by the gasesgenerated by the decomposition of the chemical blowing agent, forcingthe material into the shape of the mold The pressure and temperature ofthe material in the mold then drop, resulting in bubbles developing inthe core. In a preferred embodiment, the melt is charged at about fourhundred (400) degrees Fahrenheit and the melt temperature is betweenabout three hundred and eighty (380) degrees Fahrenheit to four hundredand fifty (450) degrees Fahrenheit. It should be noted that structuralfoam spacer blocks 11 made in accordance with teachings of the presentinvention may be made from a rubber compound in combination with aplastic. Preferably, the plastic will encapsulate the rubber particlesand act as a binder. The rubber preferably produces enough gas duringprocessing under the heat and pressure of the low-pressure injectionmolding process that the structural foam product can be made without theaddition of any type of chemical blowing agent.

[0074] Spacer block 11 of the present invention may be formed byinjection molding, preferably low-pressure injection molding, such as isused for structural foam products. Spacer block 11 may include virgin orregrind plastic or combinations thereof without any rubber. The plasticmay be selected from such polymers as polyethylene, polypropylene,polyethylene terephthalate, nylon, polyurethane, polyvinyl chloride,ABS, Acetyl, polypropylene oxide, nylon, PBT, polycarbonate,polystyrene, modified polyphenylene oxide, polyester, fiberglass fillednylon, fiberglass filled styrene, fiberglass filled SAN, acrylic,ethylene copolymers, ionomers, and polysulfone. The spacer block 11 ofthe present invention may be formed from a single type of polymer ormixtures of various polymers. Typically a chemical blowing agent in anamount less than five (5) percent, and preferably in an amount less thanone (1) percent and preferably in an amount less than one-half (½)percent may be used with one hundred (100) percent polymer compositionspacer blocks 11.

[0075] A rubber and/or elastomeric compound may be incorporated in theformulation as a substitution for up to seventy (70) percent, and morepreferably less than fifty (50) percent and most preferably from aboutforty (40) to fifty (50) percent depending upon the strength to weightratio desired and the structural properties required for a particularapplication or size of guardrail. Regrind rubber is typically lessexpensive than plastic materials. Therefore, as much as forty (40) tofifty (50) percent regrind rubber may be used in a spacer block designedfor normal impact applications or support posts 30 spaced closetogether. A composition with less than forty-five (45) percent rubbermay be desirable for applications requiring support posts 30 to bespread further apart from one another. The type of rubber may also be animportant consideration in that the rubber may be comprised of a naturalrubber or synthetic rubber, either virgin material, regrind material orcombinations thereof. Additives such as fillers and fiberglass mayfurther reduce the cost of manufacture and provide the requisitestrength. Because of the gases produced during injection molding of therubber particles, the use of a chemical blowing agent is an option andis not required when processing the plastic and rubber mixedcompositions.

[0076] One material that may be used in the construction of spacer block11 comprises one or more polymers (such as polyethylene, polypropylene,polyethylene terephthalate, nylon, polyurethane, polyvinyl chloride, andmixtures thereof), and a polymer and rubber blend. Other plasticmaterials which may be used include, but are not limited to, ABS,Acetyl, polypropylene oxide, nylon PBT, polycarbonate, polystyrene,modified polyphenylene oxide, polyester, fiberglass filled nylon,fiberglass filled styrene, fiberglass filled SAN, acrylic, ethylenecopolymers, ionomers, and polysulfone. Spacer block 11 may also beformed from a single polymer or mixtures of various polymers. Thepolymers used may be virgin material or polymers including regrindmaterials, such as reground polyethylene, ethylene. The rubber and/orelastomeric compound that may be incorporated may also include a naturalrubber or synthetic rubber, either virgin, regrind material orcombinations thereof. It is contemplated that fiberglass may also beused as an additive or substitute raw material for all or at least aportion of the plastic material. Fillers such as wood chips, sawdust,calcium carbonate may also be used. The rubber from used tires that haslong been a problem for the environment may also be used as a source ofrubber for the present invention. In a variety of embodiments, thespacer blocks themselves may be recyclable.

[0077] Another embodiment of the present invention comprisespolyethylene together with regrind rubber ranging in an amount of up toforty-five (45) percent. Yet another more preferred embodiment utilizesfrom about thirty (30) to forty-five (45) percent regrind rubber andutilizes ethylene as the binding polymer.

[0078] Yet another embodiment utilizes a powdered processing aid fromPolymer Process Technologies, Inc. in Akron, Ohio referred to by thetrademark PPT-SYS, (PPT-SYS(R) for rubber applications and PPT-SYS(P)for plastic applications), having a specific gravity of about one andone-one hundredth (1.01), a pH of about seven (7), and a melting pointrange of over six hundred (600) degrees Fahrenheit. Each of thesepowdered processing aids is a highly effective alloying agent forcompatibilizing and alloying cured rubber, virgin or regrind, to formcompounds having little or no change in physical properties.

[0079] Still another embodiment of spacer block 11 includes a blend ofat least one polymer having among its ingredients one or more of theplastic materials set forth herein mixed and molded together with atleast one rubber or elastomeric material. The ability to mold largeblocks of plastic containing virgin and/or regrind thermoplasticsobtained from such sources as reusable containers, alone or togetherwith virgin or grind rubber from used tires or other sources, provides auseful means for the disposal and recycling of waste products. Oneembodiment utilizes grind rubber in combination with one or morethermoplastics extruded or molded by low-pressure injection molding orvacuum forming. The molding process is believed to encapsulate therubber particles with the thermoplastic melt thereby providing astronger blended product with enhanced performance capabilities ascompared to a simple mixture of thermoplastic and rubber particlescompressed together under high pressure. One source of the grind rubberis used vehicle tires, as indicated above, representing a new method ofdisposal for used tires.

[0080] Another embodiment may contain a non-toxic blend of naturallyoccurring materials, (plant polymers, gums, and anionic salts), marketedby Polymer process Technologies, Inc., under the trademark of PPT-RNU.When added to post consumer plastics of all kinds, PPT-RNU willtypically repair heat history plastics to near virgin polymer conditionin addition to or instead of the PPT-SYS (R)/(P). This material has a pHof about six and eight-tenths (6.8), a specific gravity of about one andfive-hundredths (1.05), a melting point flow of over six hundred andfifty (650) degrees Fahrenheit, and it's generally used in amounts of upto ten (10) percent by weight, and more preferably, from about three (3)percent to about six (6) percent by weight.

[0081] Another embodiment utilizes both the PPT-RNU and PPT-SYSadditives with rubber and a polymer, such as polyethylene, to enhancethe compatibility and performance of regrind rubber from tires beingcompounded with virgin or recycled polymers such as polyethylene inconventional compounding equipment at processing temperatures of fromabout three hundred and sixty (360) degrees Fahrenheit to four hundredand ten (410) degrees Fahrenheit which is typical for extrusion andcompounding operations.

[0082] Although the present invention has been described with respect toa specific preferred embodiment thereof, various changes andmodifications may be suggested to one skilled in the art and it isintended that the present invention encompass such changes andmodifications fall within the scope of the appended claims.

What is claimed is:
 1. A spacer block for attaching a guardrail to asupport post, comprising: a pair of side-walls having respective firstand second ends; a top panel disposed proximate the first end of theside-walls; a bottom panel disposed proximate the second end of theside-walls; the top panel, bottom panel and side panels forming agenerally rectangular block having respective first and second faces; atleast one mounting bore traveling between the first and second face ofthe block; an engagement mechanism operably coupled proximate the toppanel, the engagement mechanism operable to engage the block with thesupport post; and a resting mechanism operably coupled proximate thebottom panel, the resting mechanism operable to support a guardrailduring assembly.
 2. The spacer block of claim 1 further comprising: amedial wall disposed between the side-walls, the medial wall positionedgenerally perpendicular to the side-walls and generally parallel to thetop and bottom panels; the medial wall, top panel and side-walls forminga first cavity; and the medial wall, bottom panel and side-walls formingsecond cavity.
 3. The spacer block of claim 2 further comprising: atleast one mounting bore traveling through the medial wall from the firstface of the spacer block to the second face of the spacer block; and themounting bore operable to align with at least one mounting aperture onthe support post.
 4. The spacer block of claim 2 further comprising areinforcement structure disposed in at least one of the cavities.
 5. Thespacer block of claim 2 further comprising a webbing structure disposedwithin at least one of the cavities, the webbing structure operable tostructurally reinforce the spacer block.
 6. The spacer block of claim 1further comprising: first and second medial walls disposed generallyperpendicular to the side-walls and generally parallel to the top andbottom panels; the first medial wall, side-walls and top panel creatinga first cavity; the first medial wall, second medial wall and sidewallsforming a second cavity; and the second medial wall, side-walls andbottom panel forming a third cavity.
 7. The spacer block of claim 6further comprising: at least one mounting bore disposed in the firstmedial wall, the mounting bore traveling between the first and secondfaces of the spacer block; and at least one mounting bore disposed inthe second medial wall, the mounting bore traveling between the firstand second faces of the spacer block.
 8. The spacer block of claim 1further comprising: the engagement mechanism including a tab operablycoupled to the top panel, the tab extending beyond the second face ofthe spacer block; at least two spaced apart fingers operably coupledproximate a distal end of the tab, the fingers extending from a bottomsurface of the tab and forming a gap between the fingers and the secondface of the spacer block; and the gap between the fingers operable toengage respective sides of a web on an I-beam support post and the gapbetween the fingers and the second face of the spacer block operable toengage respective sides of a flange on the I-beam support post.
 9. Thespacer block of claim 1 further comprising: the resting mechanismincluding a tab disposed proximate the bottom panel, the tab extendingfrom the first face of the spacer block; and the tab operable to supporta guardrail thereon during assembly of a roadway safety barrier system.10. The spacer block of claim 1 further comprising an alignmentmechanism operably coupled to at least one side-wall.
 11. The spacerblock of claim 1 further comprising the first face including a generallyflat solid surface.
 12. The spacer block of claim 1 further comprisingthe engagement mechanism slidably engaged with the top panel.
 13. Thespacer block of claim 1 further comprising the engagement mechanismremovably engaged with the top panel.
 14. The spacer block of claim 1further comprising the bottom panel including a notch disposed proximatethe second face of the spacer block, the notch operable to allowstacking of the spacer blocks.
 15. The spacer block of claim 1 whereinthe spacer block includes at least one polymer.
 16. The spacer block ofclaim 1 wherein the spacer block is formed using an injection moldingprocess.
 17. The spacer block of claim 1 wherein the spacer block isformed, at least in part, using a structural foam.
 18. A method ofmanufacturing a spacer block for attaching a guardrail to a supportpost, comprising: forming a block having respective first and secondsides, respective first and second faces, a top and a bottom; forming afirst aperture through the block, the first aperture disposed generallyperpendicular to the respective faces and generally parallel to therespective sides, top and bottom; and positioning an engagementmechanism on the block proximate the top and second face, the engagementmechanism operable to retain the block proximate a mounting positionduring assembly of a roadway safety barrier system.
 19. The method ofclaim 18 further comprising positioning a support mechanism on the blockproximate the bottom and first face, the support mechanism operable tosupport the guardrail during roadway safety barrier system assembly. 20.The method of claim 18 further comprising forming the second face of theblock such that the second face and the support post may be maintainedin generally flush engagement.
 21. The method of claim 18 furthercomprising creating at least two cavities in the second face of theblock.
 22. The method of claim 21 wherein the cavities are formed bypositioning at least one medial wall generally parallel to the top andbottom of the block and generally perpendicular to the respective sidesand faces of the block.
 23. The method of claim 22 further comprising:forming at least one aperture through each medial wall, the aperturestraveling generally parallel to the top, bottom and respective side andgenerally perpendicular to the respective faces; and the aperturesoperable to receive an attachment mechanism therethrough such that theguardrail may be coupled to the support post.
 24. The method of claim 21further comprising forming a reinforcement structure in at least one ofthe cavities.
 25. The method of claim 21 further comprising forming awebbed reinforcement structure within each of the cavities.
 26. Themethod of claim 18 further comprising forming at least one alignmentmechanism on the block, the alignment mechanism operable to engage aportion of the support post such that the first aperture through theblock is aligned proximate a corresponding aperture on the support post.27. The method of claim 18 further comprising forming a second aperturethrough the block, the second aperture disposed generally perpendicularto the respective faces, generally parallel to the respective sides, topand bottom and spaced from the first aperture with respect to the topand bottom such that the block may be used to attach a thrie-beamguardrail to the support post.
 28. The method of claim 18 furthercomprising incorporating at least one artificially created material intothe formation of the block.
 29. A guardrail support assembly comprising:a support post operable to support at least a portion of a guardrail;and a spacer block operable to maintain the guardrail a distance fromthe support post, the spacer block including a top tab operable toengage the support post and maintain the spacer block in position and amounting bore operable to receive an attachment mechanism such that theguardrail may be coupled to the spacer block and the support post. 30.The guardrail support assembly of claim 29 further comprising the spacerblock having a generally rectangular shape and at least two cavitiesdisposed therein, the cavities separated by a medial wall.
 31. Theguardrail support assembly of claim 30 further comprising the medialwall including at least one mounting bore disposed therein.
 32. Theguardrail support assembly of claim 30 further comprising a webbedreinforcement structure disposed in the two cavities.
 33. The guardrailsupport assembly of claim 29 further comprising the spacer block havingan alignment tab on respective sides thereof, the alignment tabsoperable to orient the spacer block such that the mounting bore alignswith a mounting aperture on the support post.
 34. The guardrail supportassembly of claim 29 further comprising an I-beam support post, theI-beam support post including a web disposed between respective flanges.35. The guardrail support assembly of claim 34 further comprising: thespacer block including a top tab extending beyond a rear face of thespacer block; and the top tab including a bottom surface and at leasttwo fingers extending from the bottom surface, the fingers creating agap between the rear face of the spacer block and the fingers operableto engage one flange of the support post proximate the web and a gapbetween the two fingers operable to engage the web of the support post.36. The guardrail support assembly of claim 29 further comprising thespacer block having a rest operable to support at least a portion of theguardrail in position for attachment.
 37. The guardrail support assemblyof claim 29 further comprising the spacer block including at least onepolymer among its component materials.
 38. A method for assembling aroadway safety barrier system, the roadway safety barrier systemincluding a plurality of spacer blocks, at least one guardrail segmentand a plurality of support posts, comprising: engaging a tab disposed onat least one spacer block with a support post such that the spacer blockis retained in position proximate a mounting location; aligning a firstmounting bore on the spacer block with a corresponding aperture on thesupport post; engaging at least a portion of one guardrail segment witha support mechanism disposed on the spacer block such that the guardrailsegment may be retained in position proximate the mounting location;aligning a corresponding aperture on the guardrail segment with thefirst mounting bore; and coupling the guardrail segment and spacer blockto the support post.
 39. The method of claim 38 further comprising:passing an attachment mechanism through first mounting bore, thecorresponding aperture in the guardrail segment and the correspondingaperture in the support post; and fixing the attachment mechanism inplace.
 40. The method of claim 38 further comprising positioning analignment flange disposed on the spacer block proximate an edge of thesupport post such that the first mounting bore generally aligns with thecorresponding aperture on the support post.
 41. The method of claim 38further comprising joining one end of a first guardrail segment to oneend of a second guardrail segment.
 42. The method of claim 38 furthercomprising: aligning a second mounting bore on the spacer block with acorresponding aperture on the support post; aligning a correspondingaperture on the guardrail segment with the second mounting bore; andfixing an attachment mechanism passed through the second mounting boreand the corresponding apertures on the support post and guardrailsegment in place.
 43. A roadway safety barrier system comprising: aguardrail; a support post operable to maintain at least a portion of theguardrail; a spacer block operable to position the guardrail a distancefrom the support post; the spacer block including at least one mountingmechanism therethrough, at least one guardrail rest, the guardrail restoperable to support at least a portion of the guardrail during assemblyof the roadway safety barrier system and at least one positioningmechanism, the positioning mechanism operable to depend the spacer blockfrom the support post during assembly of the roadway safety barriersystem; and an attachment mechanism disposed through a mounting apertureon the guardrail, the mounting bore and a mounting aperture on thesupport post, the attachment mechanism operable to maintain engagementbetween the guardrail, spacer block and support post.
 44. The roadwaysafety barrier system of claim 43 further comprising an alignmentmechanism disposed on the spacer block, the alignment mechanism operableto position the spacer block such that the mounting bore generallyaligns with the mounting aperture on the support post.
 45. The roadwaysafety barrier system of claim 44 further comprising: the spacer blockincluding a plurality of cavities in one face thereof, the cavitiesseparated by a medial wall; and each medial wall including at least onemounting bore.
 46. The roadway safety barrier system of claim 45 furthercomprising a reinforcing structure disposed in one or more of thecavities.
 47. The roadway safety barrier system of claim 43 furthercomprising an I-beam support post.
 48. The roadway safety barrier systemof claim 43 further comprising at least two mounting bores, the mountingbores positioned in the spacer block such that a thrie-beam guardrailmay be coupled to the support post and spacer block.
 49. The roadwaysafety barrier system of claim 43 wherein the spacer block is formedfrom at least one thermoplastic polymer.
 50. The roadway safety barriersystem of claim 43 wherein the spacer block is formed, at least in part,from a structural foam composition.